BACHELOR OF FASHION TECHNOLOGY

SUMMER TEXTILE INTERNSHIP

REPORT

SARANYA SPINNING MILLS ,NAMAKKAL

TAMILNADU

SUBMITTED BY,

PADMASRI K.J(BFT/17/940)

P.GAYATHRI(BFT/17/182)
 CERTIFICATE

This is to certify that the project report of Summer Textile Internship 2019 has been

completed by PADMASRI K.J (BFT/17/940) & P.GAYATHRI (BFT/17/182) – (Batch:

2017–2021).

This original research work carried out impartial fulfilment of the requirement for award

of the Bachelor’s Degree in Fashion Technology (Apparel Production) at National

Institute of Fashion Technology, Kannur

Padmasri K.J (BFT/17/940) P.Gayathri (BFT/17/182)

Signature of Mentor
Date:

Signature of Centre Coordinator

Date:
 ACKNOWLEDGEMENT
The Summer Internship, Part of Course Curriculum is to add value for the

student of any professional course. The NIFT student is expected to have the

Theoretical and Practical Knowledge of the industry which gives an extra confidence

in their performance. We would like to express our sincere thanks of gratitude to Mr.

P.Ashok Kumar for providing us an opportunity to do our internship project work in

their Company . We would like to express our special thanks to Mr .R.G Venkatesh

Babu for his guidance and support for completeing the internship. We would like to

express our special thanks to Mr. J.Sathiyasheelan (Production Manager )-SPINNING

DIVISION , J.Manikandan (Factory Manager ),V.Madheeswaran (Maintenance

Manager ) and B.Kavitha (Quality control ).We also express our special thanks to G.H

Balaguru (Deputy General Manager )-SIZING DIVISION,P.Jothipriya (Data Entry

Operator ),N.Sundaraj(Maintenance Manager).We also express our special thanks

toV .Satheeskumar (weaving manager -airjet loom ) and S.Pandian (weaving manager

-projectile loom )and Nadimuthu .S (warehouse manager ).we also wish to express

our gratitude to D.Soundaraajan -HR MANAGER for his guidance and support . We

sincerely thank our Mentor Mr.Rajesh Kumar Jha, Assistant Professor (National

Institute of Fashion Technology, Kannur) for their guidance and encouragement in

carrying out this project work and to the officials and other staff members of the

company who rendered their support during the period of our Project work.
 OBJECTIVE

 To understand the complete textile manufacturing process, mechanism and

to run it profitably.
 To understand the different roles played by different departments and its
relationship with the other departments.
 To understand about the smooth running of the industry.
 To achieve the practical experience in an industry using theoretical
concepts.
 CONTENT

TITLE PAGE NUMBER

1: Acknowledgement

2: Objective

3: Company Profile 1

4: Spinning

4.1 : Process Flowchart 6

4.2 : Raw Material Suppliers 7

4.3 : Process 8-17

4.4 : Types of Machine Used 18-20

4.5 :Maintenance 21-27

4.6 :Specification 28-29

5: Weaving

5.1 : Process Flowchart 31

5.2 : Process 31-40

5.3 : Types of Machine Used 41

5.4 : Types of Fabric Produced 41

 5.5 : Production 42

5.6 : Maintenance 43-44

6:Quality control

6.1 spinning quality control 46-49

6.2 weaving quality control 50-51

7: Conclusion 52
 COMPANY PROFILE

SARANYA SPINNING MILLS :

South India is well known for its natural beauty and
also famous for its textile industry.

A reputed business house from southern India, PSK Group having over 2 decades
of experience in Textile manufacturing and exports. Our textile wing, Saranya Spinning
Mills established in year of 2000 and has a strong presence in yarn, fabric and Home
Textile products manufacturing and exports, with the capability of 50 Million Meters of
fabric per annum.

Utilizing the cutting edge technology, high grade raw materials and stringent quality
assurance system, Saranya delivers the finest products to its customers.

Saranya Spinning Mills Private Limited is mainly into manufacturing the products
from superior quality Cotton, Viscose, Modal, Linen and Bemberg. Our team adopts
and incorporates the most advanced technology with hi-tech machineries. Our
company is certified from TUV SUD for Quality System, five star certification from TUV
Rhineland for women's code of conduct and 5'S' model company award from ABK -
AOTS - DOSOKAI. Day to day affairs taken care by the Managing Director Mr. P.S.K.
Ashok Kumar. To become a composite textile unit, employees over 1000 people with
the dedication of all employees equally. Our commitment is to provide high quality
products.

Saranya Spinning Mills having well-equipped with the warehouse capacity of 25000
Sq. Ft. area for storing cotton bales with precaution procedures in order to check out
damages and loss due to contamination, humidity and pests. A Bale Management
System with Linear Programming Technique ensures the consistency in quality
throughout the year

1
 ORGANIZATION STRUCTURE

MANAGING DIRECTOR

GENERAL MANAGER

DEPUTY GENERAL MANAGER

ADMIN SPINNING SIZING WEAVING WAREHOUSE PURCHASE TRANSPORT

MANAGER

ADMIN MANAGER

ACCOUNTS HRD MARKETING IT SECURITY

ASST.MANAGE ASST.MANAGE MARKETING SECURITY

MANAGER OFFICER

ASST MANAGER ASST .HRD MARKETING SECURITIES

ASSISTANT

CASHIER

2
 SPINNING

QUALITY PRODUCTION MAINTENANCE ELECTRICAL

MANAGER MANAGER MANAGER SUPERVISOR

QAD SUPERVISOR FITTERS ELECTRICIANS

SIZING(FACTORY
MANAGER )

UNIT -A UNIT -B

SUPERVISOR SUPERVISOR

OPERATOR OPERATOR

3
 WEAVING(FACTORY MANAGER)

SUPERVISOR

FITTER ELECTRICIAN

WAREHOUSE MANAGER

SUPERVISOR DATA ENTRY

PURCHASE

STORE KEEPER

ASSISTANTS LOADMAN

4
SPINNING DIVISION

5
 PROCESS FLOW CHART

BLOWROOM

CARDING

(DRAWING BREAKER)

(DRAWING
FINISHING)

SIMPLEX

SPINNING

WINDING

PACKING AND DISPATCHING

6
 RAW MATERIAL SUPPLIER

ADHITHYA BIRLA GROUP-GRASIM INDUSTRIES

PROCESS:
FIBRES USED :

100%VISCOSE STAPLE
MICROMODAL
FIBRE

BLOWROOM:
At this process the Fibres in Bale form will be loosen, opened &
cleaned. This is the starting stage of Spinning Process.

The fibers which are used are 100% viscose .the fibres are in the bale form and then
81 bales are laid per line . the time consumed for one batch is 24 hours (2 hours for
cleaning and 22 hours for machine running) .the weight of the bale is 250kg.

The bales are laid doen then the bale plucker mix them evenly into one large bed of
viscose .then the bale plucker machine suks the fibres through the air suction
system and then contamination are removed by vario,unimix and flexi .

Input -100%fibre output – 99 %(1% waste )

7
 Figure 1: BLOW ROOM Figure 2: BALE PLUCKER MACHINE

CARDING :
Carding is one of the most important operations in the Spinning process as

it directly determines the final features of the yarn, above all as far as the content of

neps and husks are also concerned.

The output of the blowroom is passed to carding machines through pipes using air

flow mechanism . the fibres after passing in the machines arrives in chute format i.e it

removes neps which is not filtered in blowroom by using roller .the input will be in chute

type then the output is produced in web format (i.e tissue ) then the final output

produced is sliver .

The sliver weighs about 6.02g/meter .the output is 97%of input

Figure 3 : CARDING

8
 PROCESS BOARD – CARDING

M/C NO COUNT HANK SPEED (mpm) CAN COLOUR

1 30 s VSF 0.90 130 YELLOW

2 30 s VSF 0.90 130 YELLOW

3 30 s VSF 0.90 130 YELLOW

4 30 s VSF 0.90 130 YELLOW

5 30 s VSF 0.90 130 YELLOW

6 30 s VSF 0.90 215 GREEN

7 30 s VSF 0.90 215 GREEN

8 30 s VSF 0.90 170 GREEN

9 30 s VSF 0.90 175 WHITE

10 30 s VSF 0.90 175 WHITE

11 30 s VSF 0.90 130 WHITE

12 30 s VSF 0.90 130 WHITE

13 30 s VSF 0.90 100 WHITE

14 60s MM 0.14 80 RED

15 60s MM 0.14 75 RED

16 60s MM 0.14 90 RED

Table 1: Process board -Carding

9
DRAWING BREAKER :

Drawing is the operation by which slivers are blended and doubled .

In this 7 to 8 carding cans are converted to 1 sliver can

Its main purpose is to improve the evenness . The draw frame’s influence on quality,

especially evenness, is highly important in yarn formation. If the draw frame is not

properly adjusted, there be effects on yarn strength and elongation. Secondly, a defect

arising at the draw frame itself can exert an effect of significant proportions on the

overall yarn formation process.

Input – Sliver and Output – Sliver

Figure 4 : DRAWING MACHINE

DRAWING FINISHER :

In this process, again the Slivers are blended, doubled and auto

levelled. This permits Combing, Drawing and Elongation of several slivers to make

them strong and uniform. The input can be 16 containers .there are 4 machines out of

which 3are double side and 1 is single side . In this the sliver weight is varied

10
compared with the breaker drawing .a scanning roller is used to sense the sliver and

correct the variations

Input – Sliver and Output – Sliver

PROCESS BOARD -DRAWING

M/C NO COUNT HANK SPEED(mpm) CAN COLOUR

1 30 S VSF 0.10 750 ORANGE

2 30S VSF(R) 0.15 500 GREEN

30S VSF(L) 0.10 550

3 30S VSF(R) 0.18 550 PINK

40S MM(L) BLUE

4 30S VSF(R) 0.10 550 BLUE

30S VSF(L) 0.10 500 RED

5 30S VSF 0.10 550 ORANGE

Table 2 : Process board-Drawing

SIMPLEX :

In this process the sliver is converted to roving . The Machine’s name used

in this process is called as Simplex.

Input – Sliver and Output – Roving

Figure 5: ROVING (SIMPLEX)

11
 PROCESS BOARD – SIMPLEX

M/C NO COUNT HANK SPEED(rpm) TPI(twists CAN BOBBIN

per inch) COLOUR COLOUR

1 30S VSF 1.02 1000 0.82 BLUE BLUE

2 30S VSF 1,02 1040 083 GREEN GREY

3 30S VSF 1.02 1000 0.82 RED BROWN

4 60S MM 1.4 1000 1.02 YELLOW PINK

5 30S VSF 0.90 1200 0.86 ORANGE GREEN

Table 3: Process board -Simplex

SPINNING :

In this process, the Roving is converted into Yarn.

Types of Spinning process:

 Ring Spinning

 Open-End Spinning

 Air-Jet Spinning

Ring Spinning is a continuous Process, Open-End Spinning is a technology for

creating yarn without using a Spindle and Air-Jet Spinning is a technique where the

staple fibres is blown by air into a rotor.

12
RING SPINNING :

 There are 20 ring frame machines out of which 16 are semi automatic

and 4 are automatic

 The manual machines have 1008 spindle and the automated machine

has 1200 spindles

 The count produces is 30s ,40s ,50s etc (according to the requirement

of buyer )

 The machines used are LMW LR 6/S AND LMW LR 9/AXL

 The output of one simplex machine is the input for 3 ring frame

machine

 Input – Roving and Output – Yarn

Figure 6: SPINNING ( RING FRAME )

13
 PROCESS BOARD -SPINNING

S.NO COUNT SPEED (rpm) TPI(Twists per inch ) BOBBIN

COLOUR

1 - - - -

2 31 s VSF HT 17000 32.32 BROWN

3 60s MM NC 16000 32.32 BLUE

4 60s MM NC 16500 32.32 BLUE

5 60s MM NC 16500 32.32 BLUE

6 30 s VSF HT 17000 32.32 BLUE

7 31 s VSF (S)T 12000 36.51 BROWN

8 40s VSF COM 17200 21.06 ROSE

9 40s VSF COM 17200 21.06 ROSE

10 31 s VSF COM 17000 17.34 ROSE

11 31 s VSF COM 17000 17.34 ROSE

12 31 s VSF COM 17000 17.34 ROSE

13 31 s VSF COM 17000 17.34 ROSE

14 31 s VSF COM 17000 17.34 ROSE

15 31 s VSF COM 17000 17.34 ROSE

16 31 s VSF COM 17000 17.34 ROSE

17 31 s VSF COM 18500 15.6 BLUE

18 31 s VSF COM 18500 15.6 BLUE

19 31 s VSF COM 18500 15.6 BLUE

20 31 s VSF COM 18500 15.6 BLUE

Table 4: Process board -Spinning

14
WINDING :

Winding is the process of transferring yarn or thread from one type of package

to another to facilitate subsequent processing. Not only must the package and the yarn

itself be suitable for production process, but also other factor such as Packing cases,

thread tension etc., must be considered.

In Winding the yarn in Ring Bobbin is converted into Cone.

TYPES OF WINDING:

 AUTO CONER

 LINK CONER

AUTO CONER :

The output of LMW LR 6/S is passed to the auto coner section where the bobbins are

converted to cones. The oblect of the auto coner is to eliminate the faults and

contamination in yarn and joining the ends with splice and winding of long and

continuous yarn into conical shape to facilitate at further process .

Figure 7: AUTO CONER

15
LINK CONER :

 The output of the LMW LR 9/AXL is passed to the link coner where auto doffing

method takes place and the bobbins are converted to cones . The spinning frame

is directly linked to the automatic winder. When the bobbins are doffed from the

spinning frame, they are placed onto the spinning frame, they are placed onto the

tray and do not need to be replaced.this provides high quality yarn with less man

power

Figure 8: LINK CONER

16
PACKING AND DISPATCHING:

The Cones are Categorised into Red

Label, Green Label, Violet Label, and so on… and A final Inspection is done and then

Packed and Dispatched.

Figure 9: PACKING AND DISPATCHING

17
 TYPES OF MACHINE USED

BLOWROOM:

 Bale plucker :LMW LA 23

 Vario : LMW LB 9/2

 Unimix : LMW LB 7/4

 Flexi cleaner : LMW LB 5/6

CARDING :

 Total :16 m/c

 Trutzschler - No of machines -5

Type : CCA -1000

 Trutzschler - No of machines -4

Type : KH 1000

 LMW LC 300 A -V3 , no of machines : 7

 SPEED :130mpm and 180 mpm

 HANK :0.90

LAP FORMATION:

 M/C USED : OMEGA LAP

DRAWING :

 RIETER -RSB D 24C

 RSB D 35

 SB D 22

18
  PSK D 24C

SPEED :550mpm

HANK:0.10

SIMPLEX:

LAKSHMI LF 1400-A, NO OF MACHINES :4

LMW LF 4280/A

SPEED : 1200rpm

HANK : 0.9 FOR VSF AND 1.4 FOR MICROMODAL

TPI: 0.8 FOR VSF AND 1.02 FOR MICROMODAL

SPINNING :

M/C USED: LMW LR 6/S CAPACITY : 1008 SPINDLES SPEED:17000rpm

LMW LR 9/AXL CAPACITY :1200 SPINDLES SPEED:18500rpm

AUTOCONER:

MURATEC , SCHLAFHORST , SAVIO

CAPACITY: 60 SPINDLES

LINK CONER:

MURATEC , SCHLAFHORST

CAPACITY: 32 SPINDLES

19
VORTEX III 870- MURATEC- OPEN END YARN

PER CONE WEIGHT- 3KG

MACHINE MODEL NO- LR9

CAPACITY:12000 SPINDLES ( BOTH LEFT AND RIGHT )

MACHINE NAME: PROCESS CONER II QPRO/USTER QUANTUM

SPEED: 1550M/MIN

EMPLOYEES IN EACH DEPARTMENT

SR. NO DEPARTMENT NO. OF WORKERS

1 Blow room 1

2 Carding 1, sweeper-1

3 Breaker drawing 1

4 Finisher drawing 2

5 Simplexx 6, sweeper-1

6 Spinning slider 14

7 Doffer 8

8 Reliever 3

9 Bobin carrier 2

10 Sweeper 2

11 Vortex 1

20
12 Autoconer 18

13 Cone carreier 1

14 Sweeper 1

15 Reliever 1

16 Link coner 1

17 Cone carrier 1

18 Packing 8

19 Manual winding 4

MAINTENANCE REPORT
BLOWROOM
SR.NO NATURE OF WORK FREQUENCY(
MONTHS )
1 Gear box oil change ( bale plucker ) 12
2 Tension pulley service ( bale plucker ) 12
3 Teeth plate change ( bale plucker ) 84
4 Beater wire mounting- unimix 10
5 Gear box oil change- unimix 12
6 Tension pulley service 12
7 Lattice assembly service 84
8 Grid bar change 36
9 Beater wire mounting- flexi cleaning 10
10 Gear box oil change- flexi clean 12
11 Tension pulley service 12
12 Fan bearing greasing 12
13 Gear box oil change ( vxl ) 12
14 Secondary filter cloth change 24
15 Primary filter steel mesh change 24
16 Waste recovery roll wire change 12
17 Bale plucker plucking roll bag changed C.b
18 Bale plucker tower changed C.b

Table 6: Blow room maintenance

21
 CARDING

SR.NO NATURE OF WORK FREQUENCY (

MONTHS )
1 Break liner lubrication 2
2 Cylinder and doffer petrol wash 2
3 Basic setting work 3
4 Coller service 6
5 Licker in wire mounting 9
6 Back stationary flat change 9
7 Cylinder and doffer grinding 12
8 Flat grinding 6
9 Fbk and all gear box oil change 12
10 Flat tops change 18
11 Under segment change 36
12 Break liner change 36
13 Flat stripper and diflector blade change 36
14 Flat cleaning fillet change 36
15 Stripping fillet change 36
16 Doffer cleaning fillet change 36
17 Tension pulley service 36
18 Front stationary flat change 36
19 Calender unit service 36
20 Flat drive toothed belt change 36
21 Cylinder doffer and rd roll wire mounting 36
22 Flat chain change 36
23 All beit change 24
24 Bottom coiler star coupling change 24
25 Back bottom twin tops change 6 ( 150 tonnes )
26 Off the card flat gtrinding 6 ( 150 tonnes )

Table 7: carding maintenance

DRAWING

SR.NO NATURE OF WORK FREQUENCY

1 Differntial gear box oil topping 3m
2 Differntial gear box oil change 9m
3 Drafting zone service 1y
4 Main shaft unit service 1y
5 Draw off roller service 1y
6 Creel service 1y
7 Coiler service 1y
8 Differential gear box service 2y

22
9 All drive belt change 9m

Table 8: drawing maintenance

SIMPLEX
SR.N0 NATURE OF WORK FREQUENCY(MONTHS
)
1 Diffrential gear box oil change 6
2 Bobin rail level checking 6
3 Bottom roll setting checking 6
4 Top roll setting checking 6
5 Top roll pressure checking 6
6 Belt shoifting mechanism checking 6
7 Creel bearing greasing 6
8 Collar cleaning 6
9 Bottom cone drum service 12
10 Top cone drum service 12
11 Drafting cone service 12
12 Head stock service 12
13 Spindle front stop oil change 6
14 Building motion mechanism service 18
15 Bottom apron change 18
16 Top apron change 24
17 False twister change 24
18 Bottom roll trueing 24
19 Positive cleaner service 24
20 Differential gear box service 60
21 Spindle trueing 36
22 Lifting lever chain weight chain change 60
23 Cam rop change 60
24 Weight rop change 60
25 Traver’s guide change 36
26 All belt change 9
27 Top arm service 60
Table 9: simplex maintenance

23
 RING FRAME

S.NO NATURE OF WORK FREQUENCY (DAYS

)
1 Duo flex service 360
2 Delay drafting service 90
3 C1 .c2 setting checking 90
4 Delay drafting oil change 180
5 Damping cylinder oil change 180
6 Head stock and drafting zone service 360
7 Long snarl piston service 360
8 Long snarl piston seal kit change 720
9 Main drive shaft star coupling change 180
10 Top variator service 90
11 Drum piston service 180
12 Variator piston service 360
13 Drum piston seal kit change 720
14 Variator piston seal kit change 720
15 Bottom variator service 360
16 Variator belt change 270
17 Traverse bar centre checking 60
18 Tin roll breaking greasing 90
19 Jackey pulley greasing (lhs and rhs ) 180
20 Spindle oil change 180
21 Top roller setting checking 180
22 Ring centering 180
23 Bottom apron change 360
24 Bottom roll trueing 360
25 Bobbin winder service 1080
26 Top apron change 360
27 Spindle tape change 720
28 Jackey pulley spring change 1800
29 Pressure hose change 720
30 Ring change 1800
31 Cradde spring shaft 1800
32 Draw bar roller bearing service (lhs and rhs 1080
)
33 Tin roll pulley centre checking 180
34 Cam lifting lever service 720
35 540 h timing belt change 360
36 36 hollow shaft bearing change 365
37 Suction tube cleaning 180
38 Top loader pressure checking 180
39 Elite apron change 360
40 Elite tube insert 720

Table 10: ring frame maintenance

24
 AUTO CONER
S.NO NATURE OF WORK FREQUENCY
1 Splicer component cleaning 3m
2 Tension assembly cleaning 3m
3 Loop gate service 3m
4 Empty tube conveyor pulley service 6m
5 Bobbin trolley wheel service 6m
6 Splicer scissor unit service 6m
7 Suction arm setting checking 1m
8 Cradde setting checking 6m
9 Rh-lh adapter greasing 6m
10 Bobbin peg centering 6m
11 Cylinder gear box play checking 6m
12 Drum roof cleaning 1m
13 Empty tube conveyor motor 12m
14 Rm magazine area cleaning 12m
15 Doffer gear greasing 12m
16 Bobbin beg shaft lubrication 12m
17 Re .do .doffer setting 12m
18 Suction arm cleaning 12m
19 Drum bearing greasing 18m
20 Brake lining change 2y
21 Ball acge change 2y
22 Cam follower bearing greasing 2y
23 Damping cylinder oil change 4y
24 Loop gate spring service 4y
25 Splicer air conduit change 7y
26 Multi jet valve cahnge 7y
27 Damping cylinder cover change 7y
28 Tenxion disk motor wheel change -
29 Cradle carrier shaft change -
30 Spindle all pu hose change 7y
(4mm,6mm,8mm,10mm)
31 Ohtc belt change -
32 1 h .adapter round guard ring change -

33 Acr.3,5 and 6 ejector modification plate -

34 Rm magazine chute (bobbin peg unit )pull -
rod play correction

Table 11: auto coner maintenance

25
 LINK CONER
S.NO NATURE OF WORK FREQUENCY
(MONTHS )
1 Auto doffer clamp cutter lubricate 1
2 Auto doffer swing cylinder lubricate 1
3 Suction shutter clg 1
4 Splicer cleaning and lubricate 3
5 Rhs bearing centre lubricate 3
6 Tray stopper air cylinders greasing 3
7 Pc bal -cone lubricate 6
8 Rhs bearing greasing 6
9 Cradle air damper service 6
10 Eject cutter service 6
11 Ejector service 6
12 Splicer and twisting pipe clg 6

Table 12: link coner maintenance

VORTEX
SNO NATURE OF WORK FREQUENCY
1 Cots buffing &uv treat 20days
2 All check points check & lubricating 1 month
3 Bottom apron replace 40 days
4 Top apron service 40 days
5 Splicer head clg and splice function check 3m
6 Spindles , n1 and n2 nozzle uv treat 3m
7 Spindle holder and cradle lifter cylinders 6m
service
8 Front bottom roll nylon coupling greasing 6m
9 Replace all drive belts 1y
10 Air mist separator element replacement 1y`
11 Traverse cam box oil change 1y
12 Replace flyer and bearing 1y
13 Replace 3 rd and 4th roll scanner 1y
14 Replace front roll nylon coupling 1y
15 Middle top roller cam and “o”plug 1y
16 Replace back bottom roll cleaner pad 2y
17 Replace all “o” rings for nozzle and spindle 2y
18 Replace cam shaft bush 2y
19 Replace 3rd and 4th roll drive belts 2.5y
20 Replace splicer reverse roll an d beh 2.5y
21 Front top roller bearing renovationa dn middle 2.5y
22 3rd bottom roller bearing replace 3y

26
23 Cradle and spindle lighter cylinders packing 3y
replace
24 Cradle air transfer unit packing replace 3y
25 Crg cam shaft keys replace 3y
26 Crg and ad suction nozzle “o” rings replace 3y
27 Crg and ad guide rollers replage 3y
28 Splicer head replace 3y
29 Crg wax opener and operate lever air cylinder 3y
30 Ad positioning plate ,pkg catcher ,operating 3y
lever ,chucker and cutter cylinders replace

Table 13: vortex maintenance

27
 SPECIFICATION:
Raw material specification-
 Fibre: - viscose
 denier: - 1.2
 Length: -38mm
 Strength: -2.8-2.9gpd
 Moisture: -13%
 Fibre manufacturer: -birla grasim
 Plant: - vilayat, gujarat

Blow room: -
 No of lots used in mixing: - minimum 5
 Blow room waste: - %1.0 to 2.0%
 No of beating points: - 2

Carding: -
 Hank:-0.095( 0.090-0.10)
 Speed:-130mpm,180mpm
 Production:- 45kg/hr and 75kg/hr
 Waste % :- 2.2-2.5%

Breaker draw frame:-

 Feed hank:-0.10
 Delivery hank:-0.10
 Speed:-700mpm

Finisher draw frame:

 Feed hank:-0.10
 Delivery hank:- 0.10( 0.0985-0.1015 )
 A %:-less than 0.5%
 U%:_ less than 2.5%
 Cv%: less than 0.6%
 Speed:-550mpm

28
Simplex:
 Feed hank:- 0.10
 Delivery hank:-1.02
 Total draft :-10
 Break draft:- 1.11
 Stretch %:- less than 0.5%
 U%:- less than 3.5%
 Speed:_900rpm
 Tpi:-0.85

Spinning:

 A.Count:-30.0
 Feed hank:-1.02
 Csp:-3000
 Imperfection:-less than 40( for thin: -50%, for thick : +50%, neps: +200%)
 Count cv %:- less than 15%
 Stregth cv %:-less than 5.0%

29
WEAVING

30
 PROCESS FLOW CHART

WARP
WINDING

SIZING

WEAVING

INSPECTION

WARP WINDING:
In Warp winding, the yarn is transferred from the spinner’s package to a
Weaver’s beam that can be placed behind a loom ready for Weaving. The main
function of Warp winding is to rewind the yarns from the spinning frame in a long
continuous length. The primary operation of warp-making is withdrawing ends from a
warping creel then they are evenly spaced and wounded onto a beam (Warper’s
Beam).

There are 2 methods of warping:

 Direct warping
 Sectional warping

The method carried out in this industry is direct warping .

It is the method of winding the total number of warp-ends in full width in a

single operation from creel bobbin.

31
Capacity of creel bobbin in SIZING A – 732

Capacity of creel bobbin in SIZING B – 832

Depending upon fabric width and ends per inch warp beams are prepared .

WARPING MACHINES USED :

 Karl mayer
 Beninger

SPEED :1200 meter /minute

BEAM SIZE USED : Depending on buyers requirement

Figure 10: DIRECT WARPING

WEFT WINDING:

Weft Winding is also known as Re-Winding. In Weft winding Baby Cones are
converted into cones for Weft. Roto-coner machines are only used in this process.

Winding is the most essential process both of yarn manufacturing and fabric
manufacturing. The main purpose of winding is to make a suitable package for both
Woven and Knitted production. The most common packages are cone and cheese
packages. Both packages are cross wound package. The winding mechanism for cross
winding is mainly of two types. They are:

 Random winding
 Precision winding

32
SIZING:

Size is a gelatinous film forming substance in solution or dispersion form, applied

normally to warp yarns. It can sometimes be applied to weft yarns. Sizing is the

process of applying the size material on yarn. A generic term for compounds that are

applied to warp yarn to bind the fibre together and stiffen the yarn to provide

abrasion resistance during weaving.

It is used to improve the breaking strength of the yarn

How size paste is manufactured:

Depending upon the fibre the size paste( starch paste) is manufactured. All the
required ingredients for the size paste is mixed in the specified quantity in a mixing
container . After that the mixed solution is passed to a cooking container where the
solution is cooked for 15 minutes at 133degree Celsius for 30s viscose. Then it is
passed to a storage container which acts as a carrier of the paste to the sizing
machines through large pipes.

S.NO INGREDIENTS MIX PARTICULARS

1 water 780litres
2 Size fix -150H 10kg
3 wax 3 kg
4 PVA 3kg
5 Arkolfils 10kg
6 Maize starch 15kg
7 Unisize - l 15kg
8 Sizelon 8kg
9 Kierlon 150ml
10 Awwax 150ml

TABLE 14: Size ingredients for 30s VSF

33
How sizing is done:

After the size paste is made it is transferred from the storage container to the size
box( Sow box ) through large pipelines. The yarns are unwinded by the machine
from the sizing creels having capacity of maximum 20 beams which are then passed
through the sow box and then passed over the drying cylinders . after the yarns are
dried they are again ready to be winded over the warper beam. Before which it goes
through leasing operation for the separation of the threads so that the ends don’t
stock together. Then the sized beams are further packed according to the buyers
demand.

Figure 11 : SIZING

MACHINES USED
BENINGER

SPEED :125meter /minute

CREEL CAPACITY: 20 BEAM

DAILY PRODUCTION : 1,20,000m (in terms of length)

12,000kg(in terms of weight )

34
MAINTENANCE REPORT -SIZING A
S.NO NATURE OF WORK FREQUENCY
WARPING
1 Check beam positioning 6days
2 Check drive belts 6days
3 Check oil level 6days
4 Check/compensating sizing 6days
5 Creel chain spray 1month
6 Creel stop motion test 1month
7 Cutter chain spray 15 days
8 Lubricate comb traverse chain 15 days
9 Lubricate quilts 6 days
10 Lubricate threaded spindle 6 days
11 Machine air cleaning 1day
BOILER
12 Tube cleaning 15 days
13 Id fan bearing greasing 15 days
MIXING
14 Mixing bearing greasing 15 days
15 Oil level checking 15days
TROLLEY
16 Trolley cleaning 1 day
HOIST
17 Whwwl greasing and rope lubricating 1month
WINDING
18 Drum bearing cleaning 15 days
19 Machine cleaning 6 days
20 Stop motion box lubricating 15 days
21 Stop motion shaft greasing 15 days

35
 SIZING
22 Beam shaft bearing greasing 1 month
23 Beam shaft cleaning 6 days
24 Chain and belt tension checking 6 days
25 Chain lubricating 6 days
26 Check brake cylinder setting 1 month
27 Check compressor air line fitting leaks 1 day
28 Check rotary joint and steam trap 1 day
29 Check system and size pipe line leaks 1 day
30 Cleaning 6 days
31 Cylinder greasing 15 days
32 Exhaust fan cleaning 1 month
33 Guide roll greasing 15 days
34 Head stock screw rod and comp spray 6 days
35 Head stock greasing 1 month
36 Size box b bearing greasing 6 days
37 Size box a bearing greasing 6 days

Table 15: sizing unit -A maintenance

MAINTENANCE REPORT -SIZING B

S.NO NATURE OF WORK FREQUENCY

WARPING
1 Check beam positioning 6days
2 Check drive belts 6days
3 Check oil level 6days
4 Check/compensating sizing 15 days
5 Creel chain spray 1month
6 Creel stop motion test 1month

36
7 Cutter chain spray 15 days
8 Lubricate comb traverse chain 15 days
9 Lubricate quilts 6 days
10 Lubricate threaded spindle 6 days
11 Machine air cleaning 1day
BOILER
12 Tube cleaning 15 days
13 Id fan bearing greasing 15 days
MIXING
14 Mixing bearing greasing 15 days
15 Oil level checking 15days
TROLLEY
16 Trolley cleaning 1 day
HOIST
17 Wheel greasing and rope lubricating 1month
18 Loading hoist cleaning 6 days
19 Loading hoist wheel greasing and rope 1month
lubricating
SIZING
20 Beam shaft bearing greasing 1 month
21 Beam shaft cleaning 6 days
22 Chain and belt tension checking 6 days
23 Chain lubricating 6 days
24 Check brake cylinder setting 1 month
25 Check compressor air line fitting leaks 1 day
26 Check rotary joint and steam trap 1 day
27 Check system and size pipe line leaks 1 day
28 Cleaning 6 days
29 Cylinder greasing 15 days
30 Exhaust fan cleaning 1 month
31 Guide roll greasing 15 days
32 Head stock screw rod and comp spray 6 days

37
 33 Head stock greasing 1 month
34 Size box b bearing greasing 6 days
35 Size box a bearing greasing 6 days

Table 16: sizing unit-B maintenance

S.NO WORK DESCRIPTION NO OF WORKERS

1 Warper 14
2 Sizer 7
3 Back sizer 7
4 Fitter 3
5 Boiler operator 7
6 Sweeper 7
7 Cone winding 12
8 Mixer 7
9 Warper assistant (cone carrier ) 7
10 Load man 12
11 Helper (maintenance ) 4
12 Fire wood 3

Table 17: employees in sizing unit -A and unit -B

AUTO DRAWING:

Draw frame is a machine for combining and drawing slivers of a textile fibre.

Actions Involved in Draw Frame.

 Drafting - It is the process of increasing length per unit weight of

sliver. It is mainly due to peripheral speed of the rollers.

 Doubling - The process of combing two or more carded sliver into a

single form is called doubling. In draw frame m/c generally six slivers

are fed to convert into one i.e. six doubling.

38
  Drawing - In the cotton industry the term is applied exclusively to
processing on the draw frame, where the operation is one of doubling

and drafting. Drawing= Drafting + Doubling.

Draw pin will help in stopping the machine if the yarn is broken.

Tasks of Draw frame:

 Equalizing

 Parallelizing

 Blending

 Dust removal

WEAVING:
The process of producing a fabric by interlacing warp and weft threads
is known as weaving. The machine used for weaving is known as weaving machine
or loom. Different fabrics are produced in Weaving Industry. These fabrics are
weaved by using various looms and related machines.

Classification of Weaving Machines:

 Shuttle - A shuttle that traverses back and forth across the loom width, inserts

the filling. Shuttles can be made of wood or plastic. Filling yarn is wound on the

quill and then it is placed in the shuttle. As the shuttle move across the loom,

the filling yarn is unwound from the pirn and lay in the shed.

 Shuttle-less

 Projectile - Projectile weaving machines use a projectile equipped with a

gripper to insert the filling yarn across the machine. The gripper projectile

39
 draws the filling yarn into the shed. The Projectile glides through the shed in

a rake- shaped guide. The Projectile is then conveyed to its original position

by a transport device installed under the shed.

 Rapier - A flexible or rigid solid element, called rapier, is used to insert the

filling yarn across the shed. The rapier head picks up the filling yarn and

carries it through the shed. After reaching the destination, the rapier head

returns empty to pick up the next filling yarn, which completes the cycle.

 Air-Jet - The weaving machines with the highest weft insertion performance

and are considered as the most productive in the manufacturing of light to

medium weight fabrics, preferably made of cotton and certain man-made

fibres.

 Water-Jet - A water-jet weaving machine inserts the filling yarn by highly

pressurized water. The relative velocity between the filling yarn and the

water jet provides the attractive force. Water-jet weaving machine can only

be used for hydrophobic fibres.

Figure 12 : AIRJET LOOM

40
 TYPE OF MACHINE USED

 Air Jet Loom

 TOYOTA – Speed-500rpm (Wider Width)

1000rpm (Narrow Width)

 Width-according to buyers requirment

 PPI-60

 Projectile Loom

 Sulzer-Sulzer Ruti – Speed-220-280 rpm

Width-340cm ( wider )

190cm ( narrow )

TYPES OF FABRIC PRODUCED:

 Plain

 Plain Satin

 reverse Satin

 Dobby

 Drill

 Twill

PRODUCTION:

 Length- 400m/ loom/ day ( Airjet )

Total length for 36 looms per day-14400m

41
  Width - 63 inches

 Length- 200m/ loom / day ( Projectile)

Total length for 18 looms per day- 3600 m

 Width - 63 inches

TYPES OF SELVEDGES:-

 Plain

 Planetry selvedge

 Clocker selvedge

Dropper type:- 0.3 mm

NO OF WORKERS IN WEAVING DEPARTMENT

SR.NO WORK DESCRIPTION NO OF OPERATORS

1 4 looms 1 operator

2 8 looms 1 helper

3 Sweeping 2 person per shift

4 Fitter 1 person per shift

5 Maintenance fitter 2 persons per shift

Table 18: Employees in weaving department

42
 MAINTENANCE

DAILY MAINTENANCE REPORT

SR.NO INSPECTION CHECK WHAT TO DO

POINT
1 Weft feelers Check for fly, size Remove fly, size dust or
dust or oil oil from the weft feeler with
accumulation smooth cloth
2 Left end fringe Check for fringe If the fringe length is out of
selvedge length-40mm the specification or correct
3 Spring tenser Check for fly,size Remove fly, size dust or
dust or oil oil from the weft feeler with
accumulation smooth cloth
4 Main nozzle Check for fly,size Remove fly, size dust or
dust or oil oil from the weft feeler with
accumulation smooth cloth
5 Right hand cutter Check for fly,size Check and clean then
dust accumulation apply oil
6 Left hand cutter Check for fly,size Check and clean then
dust accumulation apply oil
7 Centre cutter Check for fly,size Check and clean then
dust accumulation apply oil
8 Waste selvedge Check for fly , size Remove all foreign
motion dust or yarn matters from the motion
accumulation
9 Heald frame side Check for fly, size Check and clean then
guide dust accumulation apply lubricant

YEARLY MAINTENANCE
SR.NO INSPECTION CHECK WHAT TO DO
POINT
1 Right and left hand Nil Replace oil yearly
gearoing box
2 Shedding tappet Nil Replace oil yearly
box
3 Let off drive Nil Replace oil yearly
4 Take up drive Nil Replace oil yearly
5 Leno selvedge Nil Replace oil yearly
drive box

43
6 Brake Check the If the brake setting
machine stop is out of the
position yearly and specification
if the machine disassemble the
stops beyond the motor and adjust
specified postion and correct the
brake settings
7 Easing rod ends Check the easing If the looseness is
rod both side end 0.5 mm or more
for radial replace the easing
looseness or wear rod ends
yearly
8 Easing lever pins Check the easing If the looseness is
and bushing lever pin and 0.5mm or more
bushing for radial replace the easing
looseness or wear lever pin and
yearly bushing
9 Main motor Check for If any abnormal
abnormal motor noise noted
noise replace the motor
bearings

HALF YEARLY MAINTENANCE

SR.NO INSPECTION CHECK WHAT TO DO
POINT
1 Leno bobbin Check the bobbin rod for Correct the bent bobbin
holder bending and deformation rod and replace the
and its bushing for wear deformed or worm
bushing
Check the bobbin holder Correct or replace the
,tenser arm, and bobbin deformed one
rod stopper
Check the tension Correct or replace the
springs for deformation deformed or worn ones
and wear
Check the leno bobbin Replace the worn one
bushing for the wear

44
2 Centralized Check the pipes and Replace those parts if
lubrication nipples for damages damaged
system Check that the motor is If no sound is heard
working by listening to repair or replace the
the sound of operation electrical control
components, lead wires
and motor
Check that grease comes Repair the piping
to the ends of the pipes
3 Control box Check the terminals for Connect the terminals
invertor looseness firmly
Check the cables for Repair or replace the
brake or damage cables
4 Air piping ,joints Check the weaving Repair them if any air
and air machine one by one for leakage is found and
accumulator air leakage when the replace the damaged
weaving room is quite parts
5 Overall weaving Run the weaving Correct the machines if
machine machine one by one for any abnormal noise is
abnormal noise when the noted
weaving room is quite
6 Main motor Check for abnormal If any abnormal noise
motor noise noted replace the motor
bearings

45
 QUALITY CONTROL
SPINNING

CSP( COUNT STRENGTH PRODUCT):

It is mainly used for checking
the count of the yarn .In this 80 times the yarn is rounded with warp reel then the
yarn is collected in lea form which is then weighed with the weighing machine then
the desired quality of the yarn is displayed in the monitor .

WEIGHING MACHINE MODEL: AR 2130COMPANY:ADVENTURER

Figure 13: WRAP REEL

MAX CAPACITY: 210g

MIN CAPACITY :0.001g

TO CHECK THE STRENGTH CASCADE IS USED

46
 Figure 14 : CSP SYSTEM

In this the lea is kept in the machine and the maximum strength of the yarn
is checked .the result will be displayed in the monitor .

Few samples of lea are tested over this machine lets say 20 samples.

So the first sample will be fixed with upper jaw and lower jaw of the device. The
machine is started and observed until the sample is torn out. When the sample is
torn out the machine stops automatically and the reading is displayed on the monitor
. likewise the testing is done for all the 20 samples.

After calculating CSP of all the samples the average and cv% are calculated.

47
USTER TESTER:

To check the unevenness, thick and thin places and neps of

the yarn .

MACHINE : USTER TECHNOLOGIES

Figure `15 : USTER TESTER

TRASH SEPARATOR :

Figure 16 : TRASH SEPARATOR

Used to remove foreign particles from the cotton fibre

Sample testing is done by taking 100 gm of cotton and divided into 50-50 gm .first
the fibres will be separated individually and then passed through the machine.The

48
impurities like leaves or seeds are collected at the back of the machine .the micro
dust particles are collected in the front .by running the motor air is blown through the
machine then pure cotton is settled at the top . the process is done for 3 times if any
cotton fibre accidently comes along with the dust through this recycling process .
this testing is done before the blow room process . After the bales are arrived sample
testing is done for the fiber like micronaire test,uniformity test,strength test
,elongation test and moisture test .If the results of the test satisfies the bale is
accepted for further process

COMPANY: MAG solvics private limited

WRAP BLOCK :

This testing is done for carding and drawing .it is used to check the
quality of the sliver .the sliver is passed through the machine and it is rotated
manually 6 times using the handle present on side of the roller .the sliver is made
into ball form and then it is weighed .

For example : for 30s count viscose production in drawing the ball weight should be
in the range from 30.7g to 32.5 g and hank should be 0.0985 -0.1015

If the value goes beyond the specified hank level the correction can be done in the
drawing machine so that the machine itself balances the specified and current hank
value .

MOISTURE METER :this is used to check the moisture level for the fibre and yarn by
using the needle. the needle is inserted in the fiber or yarn and the moisture level is
displayed .

COMPANY:PRECITRONIC INSTRUMENTS AND CONTROL

49
 WEAVING

Inspection

Inspection can be defined as the visual examination of raw materials (such as

fabric, buttons, zippers, sewing threads, trims etc), partially finished components of

the garments and completely finished garments in relation to some standards,

specifications or requirement as well as measuring the garments to check if they meet

the required measurements.

Four-Point System is a standardized Test Methods for fabric Visually

Inspecting and Grading. Four-Point System is widest acceptance in fabric inspection

due to its practical, impartial, and worldwide recognized.

Inches Points Allotted

0 to 3” 1

3.1” to 6” 2

6.1” to 9” 3

9” and more 4

50
MACHINES :

ROLL TO ROLL INSPECTION MACHINE :3 M/C

Figure 17 : ROLL TO ROLL INSPECTION

BRAND:KINGSTONE

PRODUCTION PER DAY FOR 1 MACHINE : 7000m

CHECKING LIMIT :70”

In this machine the roll gets unwinded automatically and checking is done by the
operator manually while it passes through the inspection table and then it is
rewinded to roll form

A roller meter is placed in the machine for easy detection of where the defect has
occurred .

Bottom of the inspection table (viewing area) will be illuminated so that the defects
are analysed easily .

51
 CONCLUSION

The Textile Internship was a great learning experience for us. As textile

is one of the important area as well as this project taught us working in a team and

co-ordinating with one another. Making a detailed study and documentation was a

rich experience for us.

It was a sound exposure for us to spend valuable timeline provided by the

institution for the industry , visited various departments and understand the

procedures step by step. Textile is a very important sector and learning about the

working of the industry is a precious experience.

Through this project we were introduced to the manufacturing industry

which will help us to be prepared for our future industry-based assignments. The

subjects that we studied during our course curriculum found practical implications

during our study and hence proved that each and every subject taught to us holds

vital importance

52
 REFERENCES
http://www.saranyaspinningmills.in/
https://textilelearner.blogspot.com/

53
 LIST OF FIGURES
Figure 1: Blow room………………………………………………………………………6
Figure 2: Bale plucker machine………………………………………………………….7
Figure 3: Carding………………………………………………………………………….8
Figure 4: Drawing…………………………………………………………………………10
Figure 5: Roving…………………………………………………………………………..11
Figure 6: Simplex………………………………………………………………………… 11
Figure 7: Spinning ………………………………………………………………………..12
Figure 8: Auto coner……………………………………………………………………... 15
Figure 9: Link coner……………………………………………………………………… 16
Figure 10: Warping ……………………………………………………………………….31
Figure 11: Sizing………………………………………………………………………… 33
Figure 12: Airjet loom…………………………………………………………………… 40
Figure 13: Wrap reel………………………………………………………………………46
Figure 14: CSP system…………………………………………………………………. 47
Figure 15: Uster tester…………………………………………………………………… 48
Figure 16: Trash separator……………………………………………………………… 48
Figure 17: Roll to roll inspection m/c…………………………………………………… 51

54
 LIST OF TABLES
Table 1: Process board - Carding………………………………………… 9
Table 2: Process board – Drawing………………………………………... 11
Table 3: Process board - simplex………………………………………… 12
Table 4: Process board-Spinning…………………………………………. 14
Table 5: Employees in spinning department……………………………… 20
Table 6: Blow room maintenance………………………………………….. 21
Table 7: Carding maintenance………………………………………………22
Table 8: Drawing maintenance………………………………………………22
Table 9: Simplex maintenance…………………………………………… 23
Table 10: Ringframe maintenance………………………………………… 24
Table 11: Auto coner………………………………………………………… 25
Table 12: Link coner………………………………………………………… 26
Table 13: Vortex maintenance……………………………………………… 26
Table 14: Size ingredients for 30s vsf…………………………………….. 33
Table 15: sizing unit-A maintenance……………………………………… 35
Table 16: sizing unit-B maintenance……………………………………… 36
Table 17: Employees in sizing A&B……………………………………… 38
Table 18: Employees in weaving department………………………….. 42
Table 19: Maintenance for weaving…………………………………….. 43

55